US11342629B2 - Method for manufacturing battery module - Google Patents

Method for manufacturing battery module Download PDF

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US11342629B2
US11342629B2 US16/753,084 US201816753084A US11342629B2 US 11342629 B2 US11342629 B2 US 11342629B2 US 201816753084 A US201816753084 A US 201816753084A US 11342629 B2 US11342629 B2 US 11342629B2
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resin
resin composition
resin layer
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battery module
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US20200321565A1 (en
Inventor
Eun Suk Park
Se Woo YANG
Yoon Gyung Cho
Yang Gu Kang
Hyun Suk Kim
Hyoung Sook PARK
Sang Min Park
Young Jo Yang
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LG Chem Ltd
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LG Chem Ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/258Modular batteries; Casings provided with means for assembling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00Features of adhesives not provided for in group C09J9/00, e.g. additives
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/04Homopolymers or copolymers of ethene
    • C09J123/08Copolymers of ethene
    • C09J123/0846Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
    • C09J123/0853Vinylacetate
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J133/00Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J163/00Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J175/00Adhesives based on polyureas or polyurethanes; Adhesives based on derivatives of such polymers
    • C09J175/04Polyurethanes
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J183/00Adhesives based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Adhesives based on derivatives of such polymers
    • C09J183/04Polysiloxanes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00Secondary cells; Manufacture thereof
    • H01M10/60Heating or cooling; Temperature control
    • H01M10/65Means for temperature control structurally associated with the cells
    • H01M10/653Means for temperature control structurally associated with the cells characterised by electrically insulating or thermally conductive materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/116Primary casings; Jackets or wrappings characterised by the material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/211Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for pouch cells
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/34Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3468Batteries, accumulators or fuel cells
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00Batteries for particular applications
    • H01M2220/20Batteries in motive systems, e.g. vehicle, ship, plane
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/116Primary casings; Jackets or wrappings characterised by the material
    • H01M50/117Inorganic material
    • H01M50/119Metals
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/116Primary casings; Jackets or wrappings characterised by the material
    • H01M50/121Organic material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10Primary casings; Jackets or wrappings
    • H01M50/116Primary casings; Jackets or wrappings characterised by the material
    • H01M50/124Primary casings; Jackets or wrappings characterised by the material having a layered structure
    • H01M50/126Primary casings; Jackets or wrappings characterised by the material having a layered structure comprising three or more layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the lithium secondary battery mainly uses lithium oxides and carbon materials as positive electrode and negative electrode active materials, respectively.
  • the lithium secondary battery includes an electrode assembly in which a positive plate and a negative plate coated with a positive electrode active material and a negative electrode active material, respectively, are disposed with a separator interposed therebetween, and an exterior material in which the electrode assembly is sealed and housed together with an electrolyte, which can be classified as a can type secondary battery and a pouch type secondary battery depending on the kind of the exterior material.
  • Patent Document 1 discloses a battery module having excellent power relative to the volume while being lightweight, and having excellent heat dissipation characteristics.
  • the battery module disclosed in Patent Document 1 comprises battery cells housed in a case, where a resin layer exists between the battery cells and the case. This resin layer is formed by injecting a curable resin composition through the injection port formed in the case and then curing it in the manufacturing processes.
  • FIG. 2 is a diagram showing an exemplary module case.
  • FIG. 3 is a diagram showing a form in which battery cells are housed in a module case.
  • FIG. 4 is a diagram of an exemplary bottom plate in which injection ports and observation holes are formed.
  • FIGS. 7 and 8 are diagrams showing the structure of an exemplary battery module.
  • FIG. 9 is a schematic diagram in the form that a tape is attached so as to cover an injection port.
  • FIG. 12 is a schematic diagram of a case where a penetrating auxiliary portion is formed on a tape.
  • the present application provides a method for manufacturing a battery module. It is an object of the present application to provide a manufacturing method capable of solving a process delay or contamination of a case and the like due to a reverse discharge phenomenon that occurs when a curable resin composition is injected into an injection port.
  • the relevant physical property is a physical property measured at room temperature, unless otherwise specified.
  • room temperature is a natural temperature without warming or cooling, and usually a temperature in a range of about 10° C. to about 30° C., or about 23° C. or about 25° C. or so.
  • the unit of temperature is ° C.
  • FIG. 2 is a view showing an exemplary module case ( 10 ), which is an example of a box-shaped case ( 10 ) comprising one bottom plate ( 10 a ) and four sidewalls ( 10 b ). As in FIG. 2 , the module case ( 10 ) may further comprise a top plate ( 10 c ) sealing the internal space.
  • An injection port is formed in the bottom plate, the sidewalls, and/or the top plate of the module case.
  • Such an injection port may be formed on the bottom plate or the like which is in contact with a resin layer to be described below, and may be formed on the top plate and the bottom plate, and the like which are in contact with the resin layer.
  • the injection port is formed for a process of injecting a resin composition forming the resin layer, as described below.
  • the shape, number and position of the injection port can be adjusted in consideration of the injection efficiency of the resin composition.
  • the injection port may be formed at least on the bottom plate and the top plate.
  • the injection port may be formed at about 1/4 to 3/4 point or about 3/8 to 7/8 point, or approximately the middle, of the total length of the sidewalls, the bottom plate, or the top plate.
  • 1/4, 3/4, 3/8, or 7/8 point is, for example, a ratio of the distance (A) to the hole forming position relative to the total length (L) measured based on any one end face (E) of the bottom plate or the like.
  • the end (E) at which the length (L) and the distance (A) are formed may be any end (E) as long as the length (L) and the distance (A) are measured from the same end (E).
  • the injection port ( 50 a ) is in a form of being located at the approximately middle part of the bottom plate ( 10 a ).
  • the size and shape of the injection port are not particularly limited, and can be formed in consideration of the injection efficiency of a resin layer material to be described below.
  • the injection port may have a circular shape, an elliptical shape, a polygonal shape such as triangle or square, or an amorphous shape.
  • the number and spacing of the injection port are not greatly limited and can be adjusted so that the resin layer can have a wide contact area with the bottom plate or the like, as described above.
  • the module case may be a thermally conductive case.
  • thermally conductive case means a case having the thermal conductivity of the entire case of 10 W/mk or more, or comprising at least a portion having the thermal conductivity as above.
  • at least one of the sidewalls, the bottom plate and the top plate as described above may have the thermal conductivity described above.
  • at least one of the sidewalls, the bottom plate, and the top plate may comprise a portion having the thermal conductivity.
  • a first filler-containing cured resin layer in contact with the top plate and the battery cell, and a second filler-containing cured resin layer in contact with the bottom plate and the battery cell are included, as described below.
  • at least one resin layer of at least the first and second filler-containing cured resin layers may be a thermally conductive resin layer, whereby at least the top plate or the bottom plate in contact with the thermally conductive resin layer may be thermally conductive, or may comprise a thermally conductive portion.
  • the thermal conductivity of the thermally conductive top plate, bottom plate or side wall; or the thermally conductive portion may be about 20 W/mk or more, 30 W/mk or more, 40 W/mk or more, 50 W/mk or more, 60 W/mk or more, 70 W/mk or more, 80 W/mk or more, 90 W/mk or more, 100 W/mk or more, 110 W/mk or more, 120 W/mk or more, 130 W/mk or more, 140 W/mk or more, 150 W/mk or more, 160 W/mk or more, 170 W/mk or more, 180 W/mk or more, 190 W/mk or more, or about 195 W/mk or more.
  • the thermal conductivity may be about 1,000 W/mk or less, 900 W/mk or less, 800 W/mk or less, 700 W/mk or less, 600 W/mk or less, 500 W/mk or less, 400 W/mk or less, 300 W/mk or less, or about 250 W/mk or less, but is not limited thereto.
  • the kind of materials exhibiting the thermal conductivity as above is not particularly limited, and for example, includes metal materials such as aluminum, gold, pure silver, tungsten, copper, nickel, or platinum.
  • the module case may be comprised entirely of the thermally conductive material as above, or at least a part of the module case may be a portion comprised of the thermally conductive material. Accordingly, the module case may have the above-mentioned range of thermal conductivity, or comprise at least a portion having the aforementioned thermal conductivity.
  • the portion having a thermal conductivity in the above range may be a portion in contact with the resin layer and/or the insulating layer as described below.
  • the portion having the thermal conductivity may be a portion in contact with a cooling medium such as cooling water. According to this structure, a structure capable of effectively discharging heat generated from the battery cell to the outside can be realized.
  • the type of the battery cell housed in the module case is not particularly limited, and a variety of known battery cells may be applied.
  • the battery cell may be a pouch type.
  • the pouch type battery cell ( 100 ) may typically comprise an electrode assembly, an electrolyte, and a pouch exterior material.
  • FIG. 5 is an exploded perspective view schematically showing the configuration of an exemplary pouch type cell
  • FIG. 6 is a combined perspective view of the configuration of FIG. 5 .
  • the electrode assembly ( 110 ) included in the pouch type cell ( 100 ) may be in a form in which at least one positive plate and at least one negative plate are disposed with each separator interposed therebetween.
  • the electrode assembly ( 110 ) may be a wound type in which one positive plate and one negative plate are wound together with the separator, or a stacked type in which a plurality of positive plates and a plurality of negative plates are laminated alternately with each separator interposed therebetween.
  • the exterior material ( 120 ) may comprise an upper pouch ( 121 ) and a lower pouch ( 122 ), where in at least one of the upper pouch ( 121 ) and the lower pouch ( 122 ), a concave internal space (I) can be formed.
  • the electrode assembly ( 110 ) can be housed in the internal space (I) of this pouch.
  • a sealing portion (S) is provided on each outer peripheral surface of the upper pouch ( 121 ) and the lower pouch ( 122 ) and these sealing portions (S) are bonded to each other so that the internal space accommodating the electrode assembly ( 110 ) can be sealed.
  • Each electrode plate of the electrode assembly ( 110 ) is provided with an electrode tab, and one or more electrode tabs may be connected to an electrode lead.
  • the electrode lead may be interposed between the sealing portions (S) of the upper pouch ( 121 ) and the lower pouch ( 122 ) and exposed to the outside of the exterior material ( 120 ) to function as an electrode terminal of the secondary battery ( 100 ).
  • each of the resin layers may also be an adhesive layer.
  • adhesive layer means a case where the adhesive force of the resin layer is at least 150 gf/10 mm or more, 200 gf/10 mm or more, 250 gf/10 mm or more, 300 gf/10 mm or more, 350 gf/10 mm or more, or about 400 gf/10 mm or more.
  • the adhesive force is measured for an aluminum pouch according to a method disclosed in an example to be described below.
  • FIG. 7 is an exemplary cross-sectional diagram of the battery module, and for example, the module may be in a form which comprises a case ( 10 ) including sidewalls ( 10 b ) and a bottom plate ( 10 a ); a plurality of battery cells ( 20 ) housed inside the case and a resin layer ( 30 ) in contact with both the battery cell ( 20 ) and the case ( 10 ), as shown in FIG. 7 .
  • FIG. 7 is a diagram of the resin layer ( 30 ) existing on the side of the bottom plate ( 10 a ), but the battery module also comprises a resin layer in the form such as FIG. 7 on the side of the top plate.
  • the contact area between the resin layer and the bottom plate or the like may be about 70% or more, 75% or more, 80% or more, 85% or more, 90% or more, or about 95% or more, relative to the total area of the bottom plate or the like.
  • the upper limit of the contact area is not particularly limited, and may be, for example, 100% or less, or less than about 100%.
  • a guiding portion ( 10 d ) which can guide the housed battery cell ( 20 ) may also be present on at least one surface of the inside of the module case ( 10 ), for example, a surface ( 10 a ) in contact with the resin layer ( 30 ).
  • the shape of the guiding portion ( 10 d ) is not particularly limited, and an appropriate shape can be employed in consideration of the shape of the battery cell to be applied, where the guiding portion ( 10 d ) may be integrally formed with the bottom plate or the like, or may be attached separately thereto.
  • first and second filler-containing cured resin layers included in the battery module both may be thermally conductive resin layers having the thermal conductivity, and at least one may be the thermally conductive resin layer.
  • any one of the first and second filler-containing cured resin layers may be the thermally conductive resin layer and the other may be a resin layer having a low thermal conductivity. Such a structure may be advantageous to the heat dissipation characteristic of the battery module.
  • the first and second filler-containing cured resin layers may have a specific gravity of 5 or less.
  • the specific gravity may be about 4.5 or less, 4 or less, 3.5 or less, or about 3 or less.
  • the resin layer showing the specific gravity in this range is advantageous for manufacturing a lightweight battery module.
  • the specific gravity can be about 1.5 or more, or about 2 or more.
  • the components added to the resin layer can be adjusted so that the resin layer exhibits the specific gravity in the above range.
  • the first and second filler-containing cured resin layers have also a low coefficient of thermal expansion (CTE). This can prevent the occurrence of peeling or voids that may occur during the manufacture or use process of the module.
  • the coefficient of thermal expansion can be appropriately adjusted within a range capable of exhibiting the above-described effects, and can be, for example, less than about 300 ppm/K, less than 250 ppm/K, less than 200 ppm/K, less than 150 ppm/K or less than about 100 ppm/K.
  • the first and second filler-containing cured resin layers may also have a 5% weight loss temperature in a thermogravimetric analysis (TGA) of 400° C. or more, or an 800° C. balance may be 70 wt % or more.
  • TGA thermogravimetric analysis
  • the battery module can have more improved stability at high temperature.
  • the 800° C. balance may be about 75 wt % or more, 80 wt % or more, 85 wt % or more, or about 90 wt % or more.
  • the 800° C. balance may be about 99 wt % or less.
  • the thermogravimetric analysis (TGA) can be conducted within a range of 25° C. to 800° C.
  • thermogravimetric analysis (TGA) results can also be achieved by controlling the composition of the resin layer.
  • TGA thermogravimetric analysis
  • the 800° C. balance usually depends on the type or ratio of the fillers contained in the resin layer, and when an excess amount of the fillers is contained, the balance increases.
  • the silicone resins generally have higher heat resistance than other resins such as epoxy or urethane, the balance is higher, whereby the resin component included in the resin layer also affects the hardness.
  • the upper limit of the thickness is not particularly limited and may be, for example, about 1 mm or less, about 200 ⁇ m or less, 190 ⁇ m or less, 180 ⁇ m or less, 170 ⁇ m or less, 160 ⁇ m or less, or 150 ⁇ m or less.
  • the manufacturing method of the present application comprises a process of attaching a tape to the injection port before injecting the resin composition through the injection port. That is, the manufacturing method may comprise a step of attaching a tape to cover the injection port of the bottom plate or the sidewalls.
  • FIG. 9 is a schematic diagram of the bottom plate ( 100 a ) or sidewalls in which the tape ( 600 ) is attached to cover the injection port ( 500 ).
  • an injection device for injecting a resin composition is mounted on the injection port, following the above steps.
  • the injection device may be mounted such that the injection device is mounted on the injection port while penetrating the tape.
  • FIG. 10 Such a process is schematically shown in FIG. 10 , where the process can be performed by advancing the injection device ( 700 ) toward the tape ( 600 ) covering the injection port of the bottom plate ( 100 a ) or the like as in FIG. 10 , and as a result, as shown in FIG. 11 , while the tape is torn, the injection device can be mounted on the injection port by penetrating the tape.
  • the type of the injection apparatus to be applied in this process is not particularly limited, and a nozzle or other devices capable of injecting the resin composition may be used.
  • the resin composition may be injected into the relevant injection device.
  • the above-described reverse discharge phenomenon can be prevented by this method, or even if the reverse discharge is caused, it is possible to simply and cleanly remove the material that has been discharged reversely by removing the tape after removal of the injection device.
  • the type of the tape attached to the injection port is not particularly limited, and a suitable type may be used.
  • the tape may include paper, a polyester-based polymer film such as polyethylene terephthalate or polyethylene naphthalate, a cellulose-based polymer film such as diacetylcellulose or triacetylcellulose, an acrylic polymer film such as polymethylmethacrylate, a styrene-based polymer film such as polystyrene or an acrylonitrile/styrene copolymer (AS resin), a polycarbonate polymer film or the like.
  • a polyester-based polymer film such as polyethylene terephthalate or polyethylene naphthalate
  • a cellulose-based polymer film such as diacetylcellulose or triacetylcellulose
  • an acrylic polymer film such as polymethylmethacrylate
  • a styrene-based polymer film such as polystyrene or an acrylonitrile/styren
  • the attachment step can be performed by forming a known pressure-sensitive adhesive
  • a penetrating auxiliary portion with a smaller size than that of the injection port may be formed on the tape attached to cover the injection port may have, and in another example, a step of attaching the tape to the injection port and then forming the penetrating auxiliary portion may also be further performed.
  • FIG. 12 is an example of the case where the penetrating auxiliary portion ( 800 ) is formed, where this penetrating auxiliary portion can be performed in a known manner such as a method of making a cut on a tape.
  • a series of processes such as attachment of the tape, installation of the injection device and injection of the resin composition, may also be performed in a state where the battery cells are present in the internal space of the module case, and may also be performed in a state where they are not present, but generally, it can be performed in a state where a number of battery cells are present in the internal space.
  • a process of removing the tape that has been attached may be further performed.
  • any necessary process may be further performed, and for example, in the case where the injected resin composition is a curable resin, a process of curing the relevant resin composition may be performed, and as described above, in order to form a structure in which the first and second resin layers are simultaneously applied, the above process may be performed through the injection port of the bottom plate and the same process may also be repeatedly performed through the injection port of the top plate.
  • the resin composition may be an adhesive material as described above, and may be a solvent type, a water-based type or a solventless type, but the solventless type resin layer may be appropriate in consideration of convenience of the manufacturing process to be described below, and the like.
  • the urethane resin composition may be a two-component type comprising a main composition part containing at least a polyol or the like; and a curing agent composition part containing at least an isocyanate compound, and the resin layer may be formed by compounding such a two-component type to prepare a resin composition and curing the composition.
  • the dicarboxylic acid-derived unit is a unit formed by a urethane reaction of dicarboxylic acid with polyol
  • the polyol-derived unit is a unit formed by a urethane reaction of polyol with dicarboxylic acid or caprolactone.
  • the polyol-derived unit of Y herein is a unit derived from polyol containing three or more hydroxyl groups such as a triol unit, a structure in which the Y moiety is branched in the structure of the above formula may be realized.
  • the kind of the polyol-derived unit of Y is not particularly limited, but it may be any one or two or more selected from the group consisting of an ethylene glycol-derived unit, a propylene glycol-derived unit, a 1,2-butylene glycol-derived unit, a 2,3-butylene glycol-derived unit, a 1,3-propanediol-derived unit, a 1,3-butanediol-derived unit, a 1,4-butanediol-derived unit, a 1,6-hexanediol-derived unit, a neopentyl glycol-derived unit, a 1,2-ethylhexyldiol-derived unit, a 1,5-pentanediol-derived unit, a 1,10-decanediol-derived unit, a 1,3-cyclohexanedimethanol-derived unit, a 1,4-cyclohexaned
  • n is an integer, and the range may be selected in consideration of desired physical properties, and may be, for example, about 2 to 10 or 2 to 5.
  • m is an integer, and the range may be selected in consideration of desired physical properties, and may be, for example, about 1 to 10 or 1 to 5.
  • the molecular weight of this polyol may be adjusted in consideration of desired low viscosity characteristics, durability or adhesiveness, and the like, which may be, for example, in a range of about 300 to 2,000.
  • the molecular weight mentioned in this specification may be, for example, a weight average molecular weight measured by using GPC (gel permeation chromatograph), and unless otherwise specified herein, the molecular weight of a polymer means a weight average molecular weight.
  • the kind of the polyisocyanate contained in the curing agent composition part of the urethane resin composition is not particularly limited, but it may be advantageous that it is an alicyclic series in order to secure desired physical properties.
  • the polyisocyanate may be an aromatic polyisocyanate compound such as tolylene diisocyanate, diphenylmethane diisocyanate, phenylenediisocyanate, polyethylenephenylene polyisocyanate, xylene diisocyanate, tetramethylxylylene diisocyanate, trizine diisocyanate, naphthalene diisocyanate and triphenylmethane triisocyanate; an aliphatic polyisocyanate such as hexamethylene diisocyanate, trimethylhexamethylene diisocyanate, lysine diisocyanate, norbornane diisocyanate methyl, ethylene diisocyanate, propylene diisocyanate or tetramethylene diisocyanate; an alicyclic polyisocyanate such as transcyclohexane-1,4-diisocyanate, isoboron diisocyanate, bis(isocyanate,
  • the ratio of the polyol to the polyisocyanate in the resin composition is not particularly limited and is appropriately controlled so as to enable the urethane reaction thereof.
  • desired additives may be compounded to the main composition part and/or the curing agent composition part of the resin composition and cured.
  • the resin composition may comprise a filler in consideration of thermal conductivity, insulation, heat resistance (TGA analysis) or specific gravity, and the like as described above. If necessary, through use of an appropriate filler, the thermal conductivity in the above-mentioned range or the like can be secured.
  • the filler included in at least the thermally conductive filler-containing cured resin layer may be a thermally conductive filler.
  • thermally conductive filler means a material having thermal conductivity of about 1 W/mK or more, 5 W/mK or more, 10 W/mK or more, or about 15 W/mK or more.
  • the resin layer may comprise a thermally conductive filler having an average particle diameter in a range of about 0.001 ⁇ m to about 80 ⁇ m.
  • the average particle diameter of the filler may be about 0.01 ⁇ m or more, 0.1 or more, 0.5 ⁇ m or more, 1 ⁇ m or more, 2 ⁇ m or more, 3 ⁇ m or more, 4 ⁇ m or more, 5 ⁇ m or more, or about 6 ⁇ m or more.
  • the ratio of the filler contained in the thermally conductive resin layer or resin composition can be selected in consideration of the characteristics of the resin layer so that the above-mentioned characteristics, for example, thermal conductivity, insulation, and the like can be secured.
  • the filler may be contained in a range of about 50 to about 2,000 parts by weight relative to 100 parts by weight of the resin component or the precursor in the resin layer or the resin composition.
  • the ratio of the filler contained in the resin layer or the resin composition having low thermal conductivity can be selected in consideration of the desired thixotropy and the like.
  • the filler may be contained in a range of about 100 to about 300 parts by weight relative to 100 parts by weight of the resin component of the resin layer or the resin composition.
  • the surface treatment agent is for surface treatment of the filler introduced into the resin layer, and any of various kinds known in the art can be used without limitation as long as it can exhibit the above action.
  • the coupling agent may be used, for example, to improve the dispersibility of the thermally conductive filler such as alumina, and any of various kinds known in the art may be used without limitation as long as it can exhibit the above action.
  • a liquid type flame retardant material (TEP, triethyl phosphate, or TCPP, tris(1,3-chloro-2-propyl)phosphate, etc.) may also be used.
  • TCPP triethyl phosphate
  • TCPP tris(1,3-chloro-2-propyl)phosphate
  • silane coupling agent capable of acting as a flame retardant synergist may also be added.
  • a main composition (viscosity: about 350,000 to 400,000 cP, based on room temperature and a shear rate of 2.5/s) comprising, as a caprolactone polyol represented by Formula 2 above, a polyol, wherein the number of repeating units (m in Formula 2) is in a level of about 1 to 3 or so and as the polyol-derived unit (Y in Formula 2), ethylene glycol and propylene glycol units are included, was used as the main composition, and a composition comprising polyisocyanate (HDI, hexamethylene diisocyanate) was used as the curing agent composition (viscosity: about 270,000 to 300,000 cP, based on room temperature and a shear rate of 2.5/s).
  • HDI polyisocyanate
  • a module case having the same shape as FIG. 2 a module case having a bottom plate, sidewalls, and a top plate, made of aluminum, was used. Guiding portions for guiding installation of battery cells were formed on the internal surface of the bottom plate in the module case, injection ports ( 50 a ) for injecting the resin composition were formed at regular intervals in the central part of the bottom plate in the module case, and observation holes ( 50 b ) were formed at the end, as shown in FIG. 4 .
  • a bundle of pouches laminating a plurality of battery pouches was housed in the module case. Subsequently, the top plate was covered on the upper surface of the module case. Thereafter, as shown in FIG.
  • a tape ( 600 ) was attached so as to cover the injection port ( 500 ) of the bottom plate ( 100 a ), and a small cut was made at the center thereof to form an auxiliary portion as shown in FIG. 12 .
  • the tape ( 600 ) a tape, in which an acrylic pressure-sensitive adhesive was formed on one side of a PET (poly(ethylene terephthalate)) film having a thickness of about 30 ⁇ m to about 50 ⁇ m or so, was used.
  • a battery module was manufactured in the same manner as in Example 1, except that the tape was not attached and the resin composition was injected using the injection device directly. As a result, the reverse discharge phenomenon as shown in FIG. 1 was observed.
  • the surface of the case was scratched by the filler in the resin composition, and thus a phenomenon that the case surface was changed to black was observed, and the time for the removal took 20 minutes or more.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Battery Mounting, Suspending (AREA)
  • Secondary Cells (AREA)
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US20200321565A1 (en) 2020-10-08
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